Art of molding thermoplastic material by the injection molding method



E. MAYNARD ART OF MOLDING THERMOPLASTI C MATERIAL Dec. 26, 1950' c.

BY THE INJECTION MOLDING METHOD- '5 Sheets-Sheet 1 Filed Nov. 28, 1947 FIGJ' INVENTOR CHARLES EDGAR MNNARD az mflgmg ATTORNEYS TEMP.

Dec. 26, 1950 c. E. MAYNARD 2,535,436

ART OF MOLDING THERMOPLASTIC MATERIAL BY THE INJECTION MOLDING METHOD Filed Nov. 28, 1947 5 Sheets-Sheet 2 l 4 MIN.

INJECTION MOLD v ME OPE ING [a4 6 c I d I I l MOLD SET UP TIME PLUNGQR OUT IEMowNc, CLOSING PRESSURE ON COOLING -SPRUE ---PlEcE TIME PLUNGER IN HOLDING PRESSURE LINE - INVENTOR FIG. 5 EDGAR MAYNARD ATTORNEYS Dec. 26, 1950 c. E. MAYNARD 2,535,436

ART OF momma THERMOPLASTIC MATERIAL BY THE INJECTION MOLDING METHOD Filed Nov. 28, 1947 5 Sheds-Sheet 5 l3 CS OR CM INVENTOR CHARLES EDGAR' MAYNARD BY ATTOR EYS Dec. 26, 1950 c. E. MAYNARD 2,535,436

ART OF MOLDING THERMOPLASTIC MATERIAL BY THE INJECTION MOLDING METHOD Filed Nov; 28, 1947 5 sheets-sheet 4 MOLD 7 TO CLOSE POSITION I6 22 220 VOLT SUPPLY Ln c3 INVENTOR 1 CHARLES EDGAR MAYNARD BY I 4 ATTORN EYS Dec. 26, 1950 c. E. MAYNARD 2,535,436

ART OF momma THERMOPLASTIC MATERIAL BY THE INJECTION momma METHOD Filed Nov. 28, 1947 I I CAMS I. r -"1 v 6m fi Q I win 5 Sheets-Sheet 5 4 -I24 Q Q Q Q Q Q 6 Q Q FIG; L

I9 2I {in 2 M T a III 18 T OPEN 36 POSITION I45 i l I44 'l' E II x I38 V INVENTOR I CHARLES EDGAR MAYNARD II4 BY ATTORNEYS explanation of the electrical part of the control system to later follow.

The hydraulic injection unit consists of a ram 23 working in a smooth bored cylinder 24 (Fig. 1). A hopper 25 provides access to feed chamber 23, and ram 23 acts as an injection plunger (Fig. l) to force material into heating chamber 21, through injection chamber 28 and into mold halves 8 and 9. This is the common injection unit, however material may be plasticized by internal heat generated by friction as the material is kneaded in a mixing chamber just below the hopper and the plasticized mass dropped through a bottom gate of the mixing chamber directly in the path of the ram 23 to be forced into the mold. This method of plasticizing is more thoroughly explained in my allowed pending application, Serial No. 591,910, filed May 4, 1945, now Patent No. 2,442,368.

The common art method of plasticizing is shown in Fig. 4 wherein granules of raw thermdplastic material put into hopper 25 are plasticized in heating chamber 21 by heat from heating unit 29 and torpedo 39- as the material is forced through by ram 23 but said allowed pending application way is preferred for large size injection charges.

Molding compounds commonly referred to in the industry as thermo-pastics generally are synthetic organic materials of the following character: (1) their chief component is a resinous or cellulose-derivative binder; (2) at some stage of their use they are plasticized, i. e. either capable of being shaped or capable of being cast, and at some subsequent stage assume a more or less rigid condition; and (3) they have the common property of softening by reheating thus permitting them to be remelted and remolded. The acetates and vinyls are examples of thermo-plastics.

In the diagrammatic view of the injection molding machine (Fig. 4) granules are shown plasticized in heating chamber 2? and the mold open. As noted above, mold half 8 is the movable half of the mold in the molding operation and mold half 9 is the stationary half. Inlet manifolds CM and OS are shown in Fig. 4 with flexible tubes l2 diagrammatically indicated as connecting to cored out passageways ll of mold halves 8 and 9 respectively. In like manner drain manifolds DM and DS connect to the mold halves by diagrammatically indicated flexible tubes 14.

When the mold is in closed position and locked, the homogenous, plasticized mass is forced by ram 23 through nozzle 29 into orifice or sprue 36 of the mold and through its runways into mold cavities 3 I. In molding, the steps of a complete cycle are: to close the mold; inject the material; let the material set; open the mold; and eject the molded piece. method ram 23 is used after injection to hold pressure on the material until it sets, after which the ram is withdrawn, the mold opened and the work ejected. Temperature of the mold throughout the entire molding cycle is maintained constant.

In contrast with the prior art routine molding practice, which considers a substantially constant mold temperature highly desirable, I propose to In the conventional molding are setting or chilling periods.

vary the mold temperature in a particular way during each molding cycle. The temperature variation for the mold is timed in my method for special purposes with relation to the periods of a molding cycle. The diagram in Fig. 5 indicates the periods of an injection molding cycle of a machine such as is being considered and the new method of temperature variations for the mold integrated and related to such periods and cycle as shown by the temperature line or curve.

The periods are (a) mold closing time, (b) injection time, (0) plastic settingtime while the plunger or ram pressure is held on the material, (d) plastic setting time while the plunger is being withdrawn and the already set sprue is holding the pressure within the mold cavity in order that the material may set further before opening the mold, (e) mold opening time, (f) article removing time.

The temperature line for the time periods indicates the nature and relation of the new and useful temperature changes for the mold to those time periods. The temperature line would be different than that shown except for the practical consideration of not being able to cause temperature changes in the mold material to follow a better line, which might be done if only theory needed to be considered. As it is the temperature line indicates a continuation of the high mold temperature during the period b. The period a is used in the final step to get up to the high temperature of the mold. Both periods 0 and d When period b ends, the mold temperature begins (is made) to drop. The mold is chilled or refrigerated for this purpose until about the end of period c or untilit is certain that the sprue is set to hold the pressure and begin the period (1 when the pressure plunger begins to draw back. At or around this time, the mold begins (is made) to heat to have it hot enough to time in with the beginning of period b in the succeeding cycle.

Consider that a relatively long time is available to get the mold heated from its low temperature point to its high point to begin period b again. There are the time periods (2, e, f and a as the temperature line shows. From the curve of this line it will be seen that the average temperature of the mold for the time periods c and d is a much lower temperature than the high temperature in period b. This average can be made as low as it is practical in order to pile the refrigerating effect into the mold during period c.

As an example which is substantially correct, the time line of 4 minutes in Fig. 5 may be considered as that for a cycle to mold by the new method a plastic hair brush back and handle, the back being one of rather large cross section. The periods are marked off in substantially correct relation. In the prior art, in which the mold temperature is kept at what the operators call their constant temperature, a comparable cycle would be substantially longer. Consider first the substantially longer cycle time of the prior art, and consider the periods as marked off in the diagram as taking up substantially the correct proportions of the prior art cycle time. One object of the new invention is to shorten the prior art cycle time by a new kind of temperature control of the mold under the special circumstances mentioned above. This is done by varying the mold temperature during the cycle. The molding steps are then as follows: To close the mold; in

ject the material which has been raised to its.

molding temperature at a time when the mold temperature is substantially higher than the set ting temperature of the material; set the material by cooling the mold; open the mold; eject the piece and close the mold; heat the mold and repeat the cycle. The time periods a, b, e, f, are not changed. I'hese four, however, are all relatively short time periods. Far more than half of the time of the complete cycle is seen in periods c and (1. Together periods 0 and d make up the relatively very long plastic setting time upon which the beginning of recycling must wait. Considering these facts, it should be clear that the mold temperature for the critical but short operation period b, a period when a high mold temperature will avoid defects in the product, can be held high while the long periods c and d can be carried on to advantage with a mold temperature averaging much lower. This time saving will not interfere in any way with the quality of the product molded. It will allow the time of the cycle to be cut down substantially and makes feasible the use of a higher than usual temperature for period b. As previously stated the usual temperatue for the mold for this period is no 3 higher than that of any other period since the temperature of the mold is maintained substantially constant, usually below 140 deg. Fahr... throughout the entire cycle. The importance of having the mold at a temperature substantially higher than the setting temperature of the material at the time of injection is to assure quality molding and prevent a stratification effect within the material as warmer internal portions of flowing plastic move past portions more external which have set by contact with relatively cold mold cavity surfaces.

The prior art time line for the plastic hair brush back and handle can be out about twenty per cent or more even though the mold temperature during period b is substantially higher than the temperature normally maintained in conventional molding practice. In conventional molding, thermo-plastic material in the fluid or plasticized state literally freezes on striking the relatively cold mold. By having the mold temperature for period b, the time period of the injection operation in the cycle, in my method substantially higher than the setting temperature of the material, the flow of material into the mold for articles of large size and cross-section will be assured. The higher than usual mold temperature of the new method invention during this period will prevent the mold walls from causing any substantial chilling f the hot plastic flowinginto the cavities. Weld lines, formed when an outer layer has chilled and set before an inner layer, will be avoided. Weld lines are so named because when the inner layer sets it shows a weld with the previously set layer. Time is saved getting the material into the mold and by speeding up the setting or chilling once the material is inside the cavities.

In the time of chilling, when the mold temperature is lowered for the chilling period of the cycle, the plastic material is under static pressure in the mold. Of course, the setting of the material will be progressively from the cavity walls inward until the article has completely set. During such chilling, however, no part of the material is fiowing as it is during the injection period. Consequently there are no layers of strain be tween material moving forward inside and particularly no chilled material on the outside to cause a drag and relatively difierent speeds of 6. new between layers. The new plan is to get all the plastic into the mold cavities to completely fill them without enough heat loss to the mold walls for any chilling effect to set up weld lines. This is preferably accomplished by the same or a slightly higher mold temperature than that of the plasticize'd material entering the mold. Only after the cavities are completely filled is the chilling effect applied to set or freeze the perfectly still material. The effect is analogous to freezing water when it is perfectl still, that is, to make clear, transparent ice with absence of signs of internal strain.

A piping diagram for a control apparatus to provide heating of the mold in accordance with the temperature line of Fig. 5 is shown in Fig. 6. The function of the apparatus indicated in this diagram is to carry heating and cooling .fluid to the cored mold halves in accordance with the molding period temperature relation of the invention. At the time the mold is being heated to the right temperature for receiving the material, which temperature is one substantially higher than the setting temperature of the material, as the temperature is rising, the mold cooling fluid is turned on. Turning on the cooling fluid before the temperature reaches the right temperature for receiving the material is a practical necessity. I'his anticipation is necessary because the mold cannot instantly be reversed from temperature rise to temperature tall. So, by turning in the cooling fluid early, the temperature rises until the right injection temperature is reached, the mold is filled, and the temperature starts to fall as the injection step is completed. Although the cooling fiuid starts to enter much earlier, the actual reversal from rising to falling temperature occurs at substantially the moment the mold is. completely filled. Similarly, other changes in mold temperature are controlled so there is substantially no time lost by temperature lag.

In the piping diagram (Fig. 6), to heat the mold, compressed air enters air line 32 at A, goes through shut-off globe valve 33, pressure reducing valve 34 (if necessary) operating air pressure gage 35, and on to-solenoid operated air valves 36 and 31. The solenoids of valves 36 and 31 being energized and these valves open, air goes to diaphragm operated valves 38 and 39. Valves 38 and 38 are three-way valves and one of their ports is opened by the air pressure compressing their diaphragm spring so that steam, entering line 40 at S may go to the mold. Steam from line 40 going to the mold passes through "shut-01f gate valve 4|, is reduced from boiler pressure to proper mold heating pressure by pressure reducing valves 42 and 43, operates pressure gages 55 and 55 and goes through the open three-way valves 38 and 39 to inlet manifolds CS and CM, finally reaching the mold through flexible tubes l2 (Fig. 7). Air coming through open solenoid operated valves 36 and 31 closes the diaphragm operated one-way valves 44 and 45 so that steam passing through the mold and entering drain manifolds DS and DM is by-passed through steam traps 46 and 41 to main drain 43 at D.

To cool the mold, solenoid operated valves 36 and 31 are closed by de-energizing their solenoids thus shutting ofi air presure to diaphragm operated three-way valves 38 and 39 and diaphragm operated one-way valves 44 and 45. Steam is prevented from reaching the mold by the closing of the steam entrance port .in three)- way valves 38 and 39. Water, or other cooling fluid, entering line 49 at W; goes through strainer 50, pressure reducing valve 5I Operates pressure gage 52 and goes through the open water port of three-way valves 38 and 39 to the mold. Emergency shut-off valves 53 and 54 are providd in the water line. Water enters the mold from inlet manifolds CS and CM through flexible tubes I2 and leaves by similar flexible tubes I4 to open drain manifolds DS and DM. One-way valves 44 and 45 being open when air pressure is shut off by solenoid operated valves 36 and 31,

- water from drain manifolds DS and DM passes through these valves 44 and 45 to main drain 48 without the necessity of going through steam traps 46 and 41.

The solenoid operated valves 36 and 31, diaphragm valves 38, 39, 44 and 45 and the pressure reducing valves 42 and 43 may all be of standard type and the construction of valves of such char- 7 acter are believed sufiiciently well known to render a detailed description of them unnecessary.

Electric timers automatically energize and deenergize the solenoids of air valves 36 and 31 to cause the admitting of heating and cooling 1.

fluids (steam and water) respectively to the mold, in order to effect the useful temperature changes desired. These timers may be set to obtain the proper temperature curve according to the material or object being molded under the method of this invention.

A suitable wiring diagram is shown in Fig. 8. In this wiring diagram the internal wiring of four conventional automatic time control devices or timers is indicated within the rectangles I00, IOI, I02 and I03. Power is supplied to the timers through the external wiring shown below these rectangles, in which line I04 is one side of the power line and line I05 is the other.

Current from line I05 goes to each timer and to one side of the solenoids of the solenoid operated air valves 36 and 31. To do this, current from line I05 goes through switch S, which is a toggle switch and the master switch for the entire unit, thence through mrminal I06 of each timer to one side of solenoid I01 of each timer and one side of motor M on all timers; current also goes to one side of each air valve solenoid 36 and 31 through lines I08 and I09.

Current from line I04 goes through line IIO to one side of limit switch 20 which is open when the mold is open, as will later be explained. Current from line I04 also goes to terminal H2 and movable contact or switch II3 on each timer. With the mold open none of the timers are energized since no current goes to one side of solenoid I01 or motor M on any timer because limit switch 20 is open. But contact H4 is normally closed linking terminals H2 and H5 on timer I and timer "II. This causes current from line I04 to go from terminal II2 to terminal H and thence to air valve solenoids 36 and 31, each air valve solenoid being fed by a different timer. Timer I00 supplies air valve solenoid 36 and timer IOI air valve solenoid 31.

Line 'I I 6 also connects to terminal II5 on timer I00, but goes to dead terminal III on timer I02. Line II8 also connects to terminal II5 of timer IOI, but goes to dead terminal II! on timer I03.

When the circuit is completed to air valve solenoids 36 and 31, it causes the air valve solenoids to energize and allows steam to flow into the mold. The steam is on all the while the mold is open. When the mold starts to close, limit switch 20 is closed by a mechanical linkage from the movable half of the mold. A trip T on limit switch is moved by projection III on movable rod I8, see also Fig. 1. Movable rod I8 slides through bushing I9 which is fastened to base I of the injection molding machine as shown in Fig. 1. A projection I6 on movable mold half 8 contains a hole II (Fig. 3) through which rod I8 slidably fits so that the mold may travel back and forth in its opening and closing operation without moving rod I8 until projection I6 abuts fixed stop nuts 2I or 22 and forces movement of rod I8 to work trip T on limit switch 20. Rod I8 is threaded at the points where stop nuts 2I and 22 force the final portion of the mold travel to trip limit switch 20. This allows for adjustments in the idle or lost motion of the mold before utilizing mold travel for tripping switch 20. Closing the limit switch 20 causes current from line I04 to go to timer I00-through line IIO to limit switch 20 and by line Hi! to terminal I20 and to terminal I2I by line I22-and to timer IN by line I23. This completes a circuit through solenoid I0I of timers I00 and IM and causes solenoid I01 to close contact I24 and holds contact II4 closed by the same action-as closed contact I24. Motor M is started when contact I24 is closed.

For motor starting, current from I2I goes to contact or switch I 24, then to motor M by line I25 through three center terminals I26, I21, I28 and line I29. Current from line I05, the other side of the power line, is already applied by switch S being closed, thus completing the motor starting circuit. The same action starts motor M of timer I 0! in a like manner.

All of the above action causes timers I00 and I ill to time out." In operating these conventional timers, the operator sets the timer for the desired time interval and when the synchronous motor M starts it drives a cam arrangement in the timer until the cams trip contacts I24 and H4 after the desired interval of time. A scale on the face of the timer is calibrated for setting the timer. Contacts I24 and I I4 are opened. By opening contact I24 the motor in the timer is stopped. Opening contact I I4 deenergizes air valve solenoid 36 and 31 and cold water, or fluid, goes into the mold as explained in conjunction with the piping diagram of Fig. 6. A spring arrangement I (Fig. 11) resets the cam shaft in the timer when the motor M stops and the timer is ready for the next time cycle of operation.

Connection is made, when timers I00 and IOI (Fig. 8) trip between their terminals H2 and I I? by the closing of contact or switch II3. This causes current to go from power line I04 through terminal H2 and down to terminal I I1, thence to terminal I 20 and I2! on timers I02 and I 03- by line I3I for timer I02 and by line I32 for timer I03.

This action, just described, causes timer I02 and I03 to start their timin cycle. Since there is no connection on terminal II5 of timers I02 and I 03, there is no current goin out.

Timers I02 and I03 are allowed to run out for the length of time set on their dials. When they trip, motor M in each of these timers is de-energized and stops and contacts II3 are closed in each. This causes current from power line I04 going through terminal II2 on timers I02 and I03 to go through contact or switch II 3 to terminal III and thence to air valve solenoids 36 and 3'Iby line II6 to air valve solenoid 36 and by line H8 to air valve solenoid 31.

. opened, the movable half of the mold opening the limit switch 23" and allowing the action of spring I in the timer mechanism to reset the timers I92 and M3.

The exploded view of one of the timers (Fig. 9) indicates the operative sequence of one timer as related to the control system. The front plate I32 has dial face I33 whereon setting dial I3t may be seen. Front plate I32 also carries settin knob I35 and a series of terminals as indicated in the internal wiring diagram of Fig. 8. A timing shaft I36 carries thereon two cams. i3? and IE8 and is. driven by motor M which has a built in gear reduction unit as will later be described. Cams I 3?? and I38 operate to open switches I24. and H4 respectively. By opening switch I24 the motor M in the timer is stopped. Opening switch II de-energizes air valve solenoid 3i; and allows cooling fluid, or water, to go into the mold. Both switches are closed by the closing of limit, switch 28 when the mold closes as explained above. Solenoid It? in the timer is energized when limit switch, 26 close and solenoid It"! holds switch I 24' closed. Switch Iii is normally closed. This, wiring diagram is merely to. show the operation of a timer related to the control system. The wiring diagram of Fig. 8 shows completely how the four timers are integrated to function together in the control system. All four of the electrical timers have a well known form of control motor. A small alternatin current, synchronous motor M in each timer set into action as, above described, drives, through gear reduction mechanism including an electromagnetically-operate ed clutch, timing shaft I 36 having thereon means for actuating the switches of the system at a predetermined time after the control motor M is started. The timing shaft I38 is, turned in one direction only by the control motor M and, when so turned, winds up a spring I30 (Fig. 11) wh ch is later used to return the shaft to its initial position, when the clutch is released by de-energization of its electromagnetic-operating means on opening the control" motor circuit; to interrupt the transmission between the shaft I36 and the control motor M.

Motor M is shown in section in Fig. 10. The rotor I39 is fixed to one end of a shaft I40 which is rotatably mounted in bearings in the casing MI and which has fixed to the other end a pinion I42. This shaft is axially movable. A spring I43 moves it to the right into, and yieldingly holds it in the illustrated position, in which the pinion I42 is out of mesh with a gear I44 of a gear reduction mechanism, The latter com prises the pinion I G2, the gear I44 and a train of gears I45, which are mounted in casing Illi and drive a timing shaft I36. When the field I45 of the timing mQ or M is energized, the. rotor I39 is drawn by magnetic attraction to the left until the magnetic ring I 4'! of the rotor comes into line with the pole piece member I 38. As a result, the pinion I42 will be moved into mesh with gear I 44, and as the rotor rotates, the shaft I36 is turned at a definite time rate, for example-one revolution per minute. The pinion I42 and gear HM constitute a clutch operable by electromagnetic means comprising the field I46 and armature I39 of the timing motor. The details of the motor construction are not important to the present invention. The motor construction may, for; example, be substantially the same as i shown in the United States Patent No.1,996,3 dated April 2, 1935 to which reference is made for a more complete disclosure of the motor. As more fully disclosed in said patent, a shaded pole winding; comprisin short circuited copper rings I47 surrounding the polar projections I 23 is used for startingpurposes.

The timing shaft I36, and theswitch-opening means thereon, are shown in diagrammati cal form in Fig. 11. This shaft, as shown, carries, two cams I37 and I38 for opening the switches I24 and lit respectively. The shaft I36. can be turned in a clockwise direction by the timing motor until a stop I49, movable with the shaft, engages the right handside of afixed abutment I58. Spring I30, connected at one end to the shaft and at the other end to a, stationary member Iili, is adapted to be wound up by the clockwise rotation of the shaft. Then, when the motor field M6 is de-energized, the magnetic pull on rotor I39 is broken and spring I43 moves it into th posit on illustrated in Fig. 14, disengaging pinion I 22 from gear 544, whereupon the spring I30 will turn shaft I35. in a countercloclge wise direction back into the illustrated position, wherein the stop [4.8 abuts the left hand ide of abutment I50.

The fully automatic machinery disclosed ab ve is t st e i ient Way n w n wn t me to practice the new method invention of injeoe tion moldingcommercially. However, the new m thod is one th t can bev pr c i d by v rious sorts of apparatus-eleven by hand tools. For instance, the equipment shown in the diagram of Fi 4. may b a l m ua ly o ra d m l ng equip en and t heating a d, l n o the mold in accordance with the new temperature variation line of Fig, 5 may be accomplished by any conduction, convection or radiation means, such as electrically, direct flame, or immersion in a hot fluid for the heating, and the use of air, refrigerated fluids or solids, or other means for the cooling.

The method of my invention may also. be prac ticed by using hand adjustments, to the conventional automatic injection molding machine. Most of these routine machines have means to raise and lower mold temperature and means. to time the periods for the automatic molding cycle. These prior art variations are consistent with trying to, or holding, the mold temperature con? stant and with the variations in size and mate! rial of the products being molded, each, of which obviously do not require the same period timing in its molding cycle. So the prior art, may Well have a machine that the molder can use by hand adjustments to, Vary the mold temperature to practice my invention when the molder is. given the disclosure of my new method to guide. his practice.

In its broad scope the invention is as one can carry out by the use of more tools, In, this,

r sp c whe t e conventiona au om ti iniection molding machine is used per se but arranged to manipulate itself as taught by my disclosure it may be considered, not as a full automatic machine, but a power tool useful to perform the new method.

Having fully described my method invention, it is to be understood that I do not wish to be limited to the details herein set forth, but my invention is of the full scope of the appended ,olaims.

I claim:

1. The improvem nt n the art of molding th rmo-pla tic mater al hv the iniection molding met od such as commonly includ s the fo lo ing cycle of steps: closing the mold, injecting t e eat plast ciaed material under r s ur to fill t e closed mold. hol ing t e mo d clo-ed and holding the material n t e mold u d h d au ic pressure long enough for it to set to molded form retaining condition, opening the mold. rem ving the piece and re eating such ste s n t eir cycle all b the use of an in ection holding machine; which improvement consists in heating the mold to a temperature a ove the setting temperature of the heat plasticized mat rial when the material is injected into the mold to avoid s tting any portion of the material until the mold is filled and thus avoid weld lines, holding such high mold temperature until the mold is filled and all portions of its contents are in qu escent condition for setting, artificially chilling the mold to start the mold temperature falling toward the setting temperature of the material, substantially at the time the in ection step is finished and continuing such chilling step to lower the mold temperature substantially below the temperature at which the material will begin setting in the mold, holding the mold closed and its contents und r hydraulic pressure for the time required for setting such material to molded form retaining condition, which is necessarily much longer than the sum of the time periods of all other steps in the aforesaid cycle, beginning another mold heating step when the mold is near its said low chilling temperature, carrying on said heating step for a substantial part of said material setting period of time, opening the mold at the end of such setting period, removing the molded material, and closing the mold, while continuing said mold heating step to continue the temperature rise in the mold during the time periods of said mold opening step, said material removing step and said mold closing step to have the mold heated and ready at such aforesaid high temperature to start the injection step of thenext cycle at the high temperature of the mold and substantially as soon as the last mentioned mold closing step is completed.

2. The method of injection molding thermo plastic material which consists in heat plasticizing the material for mold injection, heating an injection mold above the temperature at which the plasticized material can set when injected, injecting the material into the mold under the conditions of such high mold temperature, causing said mold temperature to start drop ping rapidly by artificial chilling, as soon as the mold is filled, to and below such material setting temperature, holding the mold closed and its contents under hydraulic pressure long enough for the material to set enough to maintain its molded form, continuing said artificial chilling of the mold during the first, and for a substantial part, of said material setting time and then heating said mold for the remaining and during another substantial part of said material setting time, such heating time and action being long enough to bring the molding surfaces from their low chilling temperature back to a temperature near to the plasticizing temperature of the material, opening such mold and removing the molded contents before it is heated enough to be replasticized, closing the mold to start another molding cycle, and continuing the rise of mold temperature during the mold opening and closing steps, by said heating step to have the mold at the aforesaid hi h molding temperature before or at substantially the same time as the mold closing step is finished for the following injec- 5 tion step to begin to repeatthe cycle as pointed out above.

3. The method of molding plastics of the ornamental kind which set by cooling and commonly known as thermo-plastics to distinguish them from the thermo-setting materials which are not of such generally ornamental character as the thermo-plastic kind, the method being carried out by the use of an in ection molding machine and which method consists in the following steps to shorten the time of each cycle and substantially increase the production output of such a molding machine, first raising the tem perature of the material and the tem erature of the injection mold of the machine to their molding temperatures and making the temperature of the mold substantially higher than the setting temperature of the material, while maintaining such temperatures, in ecting the material to completely fill the mold, as soon as the mold is filled and while material is held under its injection pressure, causing the mold temperature to fall rapidly by artificially chilling the mold to a temperature substantially below the setting temperature of the material, before the material sets enough to keep its molded form, starting to tioned to receive a new injection filling and repeat th cycles of steps pointed out above.

' CHARLES EDGAR MAYNARD.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Cal Num er Name Date 2,043,584 Husted June 9, 1936 2,359,013 Tucker Sept. 26, 1944 OTHER REFERENCES 5 Tenite, Tennessee Eastman Corp., published Mar. 4, 1946, page 33.

Certificate of Correction Patent No. 2,535,436 December 26, 1950 CHARLES EDGAR MAYNARD It is hereby certified that error appears in the above numbered patent requiring correction as follows:

In the grant, lines 2 and 14, and in the heading to the printed specification, line 6, name of assignee, for The Pro-Phy-Lac-Tic Brush Company read Pro-Phy-Lao-Tic Brash Company; column 11, line 12, for holding read molding; and that the said Letters Patent should be read as corrected above, so that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 20th day of February, A. D. 1951.

THOMAS F. MURPHY,

Assistant Commissioner of Patents. 

